IP Library Patent Application 14409430
Patent Application
App. No. 14/409,430

METHOD OF PURIFYING SILICON

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Quick Facts
Patent No.
US None
App. No.
14/409,430
Abstract

A method comprises forming a first molten liquid from a solvent metal and sodium carbonate, contacting the first molten liquid with silicon to form a second molten liquid, cooling the second molten liquid to provide silicon crystals and a mother liquor, and separating the silicon crystals from the mother liquor.

Claims (39)

1 . A method comprising:

(a) forming a first molten liquid from a solvent metal and at least one of sodium, sodium carbonate, and sodium oxide;

(b) contacting the first molten liquid with silicon to form a second molten liquid;

(c) cooling the second molten liquid to provide silicon crystals and a mother liquor; and

(d) separating the silicon crystals from the mother liquor.

2 . (canceled)

3 . The method of claim 1 , wherein the silicon crystals are at least partially purified from phosphorous.

4 . The method of claim 1 , wherein the silicon that contacts the first molten liquid is metallurgical grade silicon.

5 . The method of claim 1 , wherein the silicon that contacts the first molten liquid has a phosphorous level up to about 60 ppmw.

6 . The method of claim 1 , wherein the silicon that contacts the first molten liquid has a boron level up to about 15 ppmw.

7 . The method of claim 1 , wherein the silicon crystals separated from the mother liquor comprises less than about 4 ppmw phosphorous.

8 . The method of claim 1 , wherein the silicon crystals separated from the mother liquor comprises less than about 3 ppmw phosphorous.

9 . The method of claim 1 , wherein the solvent metal comprises at least one of copper, tin, zinc, antimony, silver, bismuth, aluminum, cadmium, gallium, indium, magnesium, lead, and an alloy thereof.

10 . (canceled)

11 . The method of claim 1 , wherein the solvent metal comprises aluminum, and is employed in the first molten liquid in an amount of about 99.70 wt. %.

12 . The method of claim 1 , wherein the at least one of sodium, sodium carbonate, and sodium oxide is employed in the first molten liquid in an amount of about 0.30 wt. %.

13 . The method of claim 1 , wherein the first molten liquid is contacted with silicon in a weight ratio of about 1200:1000 of silicon to first molten liquid.

14 . The method of claim 1 , wherein the cooling of the second molten liquid to provide the silicon crystals and the mother liquor is carried out to a temperature above the solidus temperature or at a temperature between the solidus and the liquidus temperature.

15 - 16 . (canceled)

17 . The method of claim 1 , wherein the silicon crystals separated from the mother liquor comprise less than about 1,500 ppmw aluminum.

18 . (canceled)

19 . The method of claim 1 , wherein any one or more of steps (a)-(d) is repeated one or more times.

20 . The method of claim 1 , wherein each of steps (a)-(d) is independently repeated one or more times.

21 . (canceled)

22 . The method of claim 1 , wherein the mother liquor comprises at least about 1,000 ppmw aluminum.

23 . (canceled)

24 . The method of claim 1 , wherein sodium oxide is formed in situ, from sodium carbonate.

25 . The method of claim 1 , wherein sodium carbonate is formed in situ.

26 . (canceled)

27 . The method of claim 1 , wherein the at least one of the sodium, the sodium carbonate, and the sodium oxide evolves or releases carbon dioxide (CO 2 ) from the first molten liquid.

28 . A method for purifying metallurgical grade silicon with a phosphorous level up to about 60 ppmw and a boron level up to about 15 ppmw, the method comprising:

(a) forming a first molten liquid from a solvent metal and sodium carbonate, wherein the solvent metal comprises aluminum;

(b) contacting the first molten liquid with silicon to form a second molten liquid;

(c) cooling the second molten liquid to provide silicon crystals and a mother liquor; and

(d) separating the silicon crystals from the mother liquor;

wherein the silicon crystals separated from the mother liquor comprises less than about 4 ppmw phosphorous;

wherein the silicon crystals separated from the mother liquor comprise less than about 3,000 ppmw aluminum; and

wherein the mother liquor separated from the silicon crystals comprise at least about 1,000 ppmw aluminum.

29 - 30 . (canceled)

Assignments (6)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 26, 2023
From: SUNNUVELLIR SLHF
To: HIGHLAND MATERIALS, INC.
Reel/Frame 064388/0757 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 25, 2023
From: SILICOR MATERIALS, INC.
To: SUNNUVELLIR SLHF
Reel/Frame 062511/0046 →
LIEN Recorded May 26, 2017
From: SILICOR MATERIALS, INC.
To: SCHWEGMAN, LUNDBERG & WOESSNER, P.A.
Reel/Frame 042592/0974 →
SECURITY INTEREST Recorded Dec 27, 2016
From: SILICOR MATERIALS, INC.
To: SUNNUVELLIR SLHF
Reel/Frame 040777/0104 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 21, 2016
From: MANCINI, PAUL A.
To: SILICOR MATERIALS INC.
Reel/Frame 037552/0939 →
LICENSE Recorded Oct 13, 2015
From: SILICOR MATERIALS, INC.
To: SMS GROUP GMBH
Reel/Frame 036811/0327 →